Configurable, repairable, and recyclable cargo pallet

ABSTRACT

The present invention relates to a lightweight and versatile pallet and its manufacturing and assembling method. It consists of the design of a repairable, recyclable, and reusable pallet with a modular structure, configurable load capacity, and with non-slip rubber surfaces to prevent sliding of the cargo on the pallet and of the pallet on the ground, shelf, and forklift or other pallet handling equipment. This pallet is to be used in numerous commercial and industrial applications. An embodiment of the platform members used to form the bottom and top surfaces of the pallet can be used to construct other flat platforms such as walls, floors, and molds for pouring concrete structures.

OTHER RELATED APPLICATIONS

The present application is related to pending PCT application No.PCT/CR09/000,001, filed on Dec. 18, 2009, belonging to the sameapplicant, Edgar Hidalgo Vargas.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a configurable, repairable, recyclable,and adjustable load capacity cargo pallet and to its manufacturing andassembling method.

2. Description of the Related Art

The applicant considers that the closest references correspond to thereferences discussed below. However, they differ from the presentinvention in that none of them disclose a simple design of a repairable,recyclable, and reusable cargo pallet with the followingcharacteristics:

-   -   a) A modular structure with configurable load capacity by        varying the robustness and/or the number of the components that        make up the new pallet.    -   b) Non-slip rubber surfaces are used to prevent sliding of the        cargo on the pallet and of the pallet on the ground, shelf, or        forklift.    -   c) Platform members that are identical on the top and bottom of        the new pallet are engaged to central beams through conical        protuberances on the beams that are accommodated on        corresponding conical holes in the platform members. These        conical protuberances contribute to carry shear stresses and to        prevent relative motion of the platform members and the beams.    -   d) Platform members with connecting means to form walls, floors,        molds for pouring concrete, and other similar structural        applications.

The applicant herein, Edgar Hidalgo Vargas, has pending patentapplication number PCT/CR09/000,001. Patent application PCT/CR09/000,001claims a manufacturing method and the configuration of structuralmembers to construct recyclable lightweight pallets that haveconfigurable load capacity for multiple applications. However, in thepresent invention, the new pallet is partially based on the inventiondisclosed in the PCT/CR09/000,001 patent application, incorporatingchanges and innovations to create a new pallet that is more versatileand with a more efficient manufacturing process. The main differencesbetween this invention and the patent application PCT/CR09/000,001 arethat the new invention is characterized by: a) having conicalprotuberances along central beams that are inserted into correspondingconical holes in platform members to obtain stability, engagement, andrigidity of the pallet; b) having platform members that are allidentical and are placed on both the top and bottom sides of the pallet,and with non-slip rubber blocks that protrude out from both sides of theplatform members; and c) having central beams designed to replace thespacers, or legs, of patent application PCT/CR09/000,001, in order tocreate a simpler modular pallet with greater load capacity.

In U.S. Pat. No. 5,458,069 for a plastic skid and method of manufacture,the patentee discloses a skid, or pallet, made with central rails andcross members or runners perpendicularly connected to the rails at thetop and bottom of the rails. The cross members are connected to therails through the rail posts that are inserted into corresponding runneropenings to which the posts are welded. As another option of connectingsuch runners to the rails, the posts are threaded and the runners havecorresponding openings to receive such threaded posts and to fasten themwith threaded nuts that lock the runners onto the rails. The rails haveflanges and reinforcing ribs along both sides of their webs; the railshave two channels at their bottom side to insert a forklift tomanipulate them. However, it differs from the present invention in thatit does not have the characteristics mentioned above at the beginning ofthis section.

In U.S. Pat. No. 6,837,170 B2 for a modular pallet, the patenteediscloses a pallet made with central stringers and deck members orrunners perpendicularly connected to the stringers at the top and bottomof the stringers. The deck members are connected to the stringersthrough grooves, locking buttons, and locking sockets that on the topand bottom sides of the stringers are used for interlocking themselveswith the deck members. The stringers have flanges and reinforcing ribsalong both sides of their webs; the stringers also have two channels attheir bottom side to insert a forklift to manipulate them. However, itdiffers from the present invention in that it does not have thecharacteristics mentioned above at the beginning of this section.

In US patent publication No. 2008/0105168 A1 for an assembly typepallet, the applicant discloses disassemblable pallets formed bysingle-piece platforms, or as other options, by platforms made with agrid structure obtained by connecting several deck boardsperpendicularly to each other. Such platforms or grid structures make upthe superior and inferior pallet surfaces, which are separated bycylindrical or rectangular spacing legs, and they are connected bythreaded means to join such platforms while maintaining the spacing legsbetween the two platforms. However, it differs from the presentinvention in that it does not have the characteristics mentioned aboveat the beginning of this section.

In Patent WO 97/17263, the patentee discloses a disassemblable palletmade with single-piece platforms to form the superior and inferiorsurfaces of the pallet, separated, and connected with blocks withengaging means to join both platforms and form the pallet. However, itdiffers from the present invention in that it does not have thecharacteristics mentioned above at the beginning of this section.

In U.S. Pat. No. 6,352,039 for a plastic pallet, the patentee disclosesa pallet made of thermoplastic material, which is formed byinterconnecting several members without using mechanical connections butinstead using adhesives or thermal welding. However, it differs from thepresent invention in that it does not have the characteristics mentionedabove at the beginning of this section.

In U.S. Pat. No. 5,337,681 for a recyclable plastic pallet, the patenteediscloses a plastic recyclable pallet made by perpendicularlyinterlocking slats and rails. However, it differs from the presentinvention in that it does not have the characteristics mentioned aboveat the beginning of this section.

In U.S. Pat. No. 4,843,976 for a plastic pallet, the patentee disclosesa plastic pallet formed by two single-piece platforms with flat surfacesand joined by cylindrical spacers with interlocking connecting features.However, it differs from the present invention in that it does not havethe characteristics mentioned above at the beginning of this section.

In U.S. Pat. No. 4,597,338 for a pallet, the patentee discloses aplastic pallet formed by two single-piece platforms with flat surfaces,but joined by rectangular spacers that interlock to the platforms toform the pallet. However, it differs from the present invention in thatit does not have the characteristics mentioned at the beginning of thissection.

Even though several pallets have been designed in the past, theapplicant believes that none of them discloses a design of a repairable,recyclable, and reusable cargo pallet with a modular structure,configurable load capacity, and with non-slip rubber surfaces to preventsliding of the cargo on the pallet and of the pallet on the ground,shelf, and forklift. In addition, the platform members of this inventionform other platforms to construct walls, floors, molds for pouringconcrete, and other similar applications.

Other documents describing the closest subject matter provide for anumber of more or less complicated features that fail to solve theproblem in an efficient and economical way. None of these patentssuggest the novel features of the present invention.

SUMMARY OF THE INVENTION

This invention is a new cargo pallet that is repairable, reusable,recyclable, lightweight, robust, and configurable to different loadcapacities to transport and store a great variety of loads. Thisinvention consists of an industrializable pallet and its manufacturingand assembling process to substitute traditional wooden pallets;consequently, a positive impact on the environment is achieved bypreventing deforestation. The pallet of this invention is a versatile,low-cost, long useful life, robust, and non-slip pallet, to be not onlyacceptable to replace wooden pallets but also to improve them whileperforming the same or similar functions. While the wooden pallets aredisposable, the plastic pallets of this invention are to be continuouslyreusable, and if an entire pallet or some of its parts are damaged, theycan be repaired, and the damaged parts can be recycled. Other advantagesof the plastic pallets in this invention, with respect to woodenpallets, are that they do not produce splinters and they do not needthermal or chemical treatments. The new pallet is built with strong andlasting components to obtain a long useful life of the pallet; theconnection of the components in made in such a way to avoid deformationsof the pallet when the pallet is subjected to impacts or under normaluse.

The pallet of this invention is to transport and store loads and it isconstructed with central beams with an I-shaped cross section and withplatform members, or deck boards, with a U-shaped cross section. Both,the platform members and the beams have flat surfaces connected withgrids of reinforcing ribs that are interconnected and run longitudinal,transversal, and diagonally along their entire length. The platformmembers and the beams are perpendicularly coupled to each other, withthe platform members at the bottom and top sides of the beams; severalplatform members in parallel create the top and bottom platforms of thepallet. Since the new pallet is made with identical platform members atits top and bottom, the pallet could be reversible depending on thenumber of platform members that are connected at its top and its bottomsides. Empty spaces are created between the bottom and top platforms ofthe pallet in order to allow its manipulation with forklift or similarhandling equipment.

The thickness of the flange and web of the central beams, thickness ofthe walls of the platform members, and thickness of the reinforcing ribsalong the beams and the platform members can be adjusted in themanufacturing process to make the beams or platform members more or lessrobust. To prevent sliding of the cargo on the pallet and of the palleton the ground, shelves, or forklift, non-slip rubber blocks are insertedin several places along the platform members. The I-shaped beams of thepallet have a row of conical protuberances, or conical pins, centeredalong their flat top and bottom surfaces, and they are used to createinterference and engagement action with the platform members when suchconical protuberances are inserted in the corresponding conical holes onthe flat surfaces of the platform members to avoid relative displacementor rotation between the beams and the platform members and to contributecarrying shear stresses between the platform members and the beams.These conical protuberances are also used to keep the main components ofthe pallet together in a stable manner even when small dimensionalchanges occur due to possible variations in temperature, loads, orstress relaxation. The beams are assembled parallel to each other byconnecting platform member perpendicular to the beams to form the topand bottom non-slip platforms of the pallet to transport or store cargo.The beams are separated to leave empty spaces that are used tomanipulate the pallet by allowing inserting the forks of forklifts orsimilar material handling equipment. Between each pair of said conicalprotuberances of the beams, there is a hole that coincides with anotherhole in the platform members when they are aligned to be coupled; suchholes might be threaded or not and are used to insert bolts thatstrongly connect and fasten the platform members and the beams to formthe pallet. Therefore, the platform members and beams of the new palletare characterized by having holes that coincide and are evenly spaced toattach them with bolts, washers, and nuts. The flat sides of theplatform members have corresponding conical holes to insert said conicalprotuberances of the beams, and between each pair of these conicalholes, there are holes of larger diameter to insert the bolts andaccommodate the washers and nuts used to connect the beams and theplatform members.

This invention is a new adjustable load capacity pallet constructed byinterconnecting and interlocking beams and platform members made throughthe plastic injection molding method. The adjustable load capacity ofthe pallet can be achieved in numerous ways, by varying the thicknessesof the walls and/or the reinforcing ribs of the beams and/or platformmembers and by varying the number of beams and/or the number of platformmembers at the top and/or bottom of the pallet. The platform membershave U-shaped cross section and flat ends and they have a grid ofinterconnected reinforcing ribs that runs perpendicular, longitudinal,and diagonally along the members from one end to the other. The centralbeams of the pallet are constructed with U-shaped cross section, flatends, and with a grid of interconnected reinforcing ribs that runs ateach side of the web of the beam in a perpendicular, longitudinal, anddiagonal way along the length of the beams. Centered along the beams,and on the top and bottom surfaces, there are rows of conicalprotuberances required to be inserted into corresponding conical holesin the flat surfaces of the platform members to speed up the palletassembling process and to facilitate alignment and engagement betweenthe beams and the platform members, and to maintain a stable and robustconnection that prevents slippage or relative rotation between thecentral beams and the platform members.

The platform members for the new pallet can be used to build platformsfor other applications, for example, they can be connected to buildwalls, floors, and molds or retention walls for concrete pouring such asin the construction of houses, sidewalks, columns, and similar.

Other features of this invention are presented in the following sectionsof the description of the invention, which gives a detailed explanationwith reference to the accompanying drawings in order to fully disclosethe invention, but without intending to impose limitations to it.

BRIEF DESCRIPTION OF THE DRAWINGS

With the above and other related objects in view, the invention consistsin the details of construction and combination of parts to form a cargopallet as will be more fully understood from the following description,when read in conjunction with the accompanying drawings in which:

FIG. 1 represents an embodiment of pallet 10, constructed with centralbeams 2 that are placed parallel to each other and connected to platformmembers 1 that are perpendicularly attached to the central beams 2 attheir top and bottom sides. The load capacity of the pallet 10 isconfigurable depending on the thicknesses of web 29, ribs 3 and 9, andthe other walls of beams 2 and members 1, and/or the number of centralbeams 2 and/or number of platform members 1 at both sides of the centralbeams 2. FIG. 1 presents a pallet model 543, meaning that it has 5platform members 1 on the top, 4 central beams 2, and 3 platform members1 at the bottom of the pallet 10.

FIG. 1A shows an enlarged section of pallet 10 with a view of holes 7and 11.

FIG. 2 shows a pallet 10 model 743, meaning that it has 7 platformmembers 1 on the top, 4 central beams 2, and 3 platform members 1 at thebottom of the pallet 10.

FIG. 3 shows details of the platform members 1, with the grid of ribs 9that run along the length of the platform members 1, with holes 4 thatare used to insert non-slip rubber blocks 5, holes 7 are used to insertbolts 12 or 22, the accommodations 15 are used to place the washers 13,the heads 18 of bolts 12 or 22, and the nuts 14; it also shows severalconical holes 11. Some bolts 12 are fully threaded, like bolt 22, and insuch case, they require that holes 6 and 7 be also threaded.

FIG. 3A show bolts 12 and 22, washers 13 and nuts 14 used to connect theplatform members 1 to the central beams 2 to form the pallet 10.

FIG. 3B shows a non-slip rubber block 5 which are inserted onto holes 4in platform members 1.

FIG. 4 is a view of the pallet 10, model 543, showing the lateral sidesof the central beams 2, with web 29, and the grid of ribs 3 connectedalong the central beams 2; also, there are conical protuberances 8,which are required to align and engage beams 2 to the platform members1, these conical protuberances 8 of the beams 2 are inserted in theconical holes 11 of platform members 1 to prevent slippage and relativerotation of the beams 2 and platform members 1; said conicalprotuberances 8 and the conical holes 11 are required to maintain astable connection between the beams 2 and platform members 1 even incritical operating conditions involving changes in temperature andloading conditions.

FIG. 4A is a view of the pallet 10, model 743, showing the lateral sidesof the central beams 2, with web 29, and the grid of ribs 3 connectedalong the central beams 2; also, there are conical protuberances 8.

FIG. 4B shows an enlarged view of a single conical protuberance 8 on thecentral beams 2.

FIG. 5 is a view of pallet 10 that is perpendicular to the view shown inFIG. 4, and it presents the assembly of the platform members 1 andcentral beams 2, the non-slip rubber blocks 5, and the empty spaces 23to insert the forks of a forklift truck or other pallet handler.

FIG. 6 presents platform members 1′, which represent another embodimentof platform members 1 but without the holes 4, and they are attached toeach other with connecting pieces 24, bolts 25 and nuts 26 to form flatplatforms 20 of configurable size depending on the number of members 1′and connecting pieces 24 used to construct it.

FIG. 6A represents the cross sectional view AA in FIG. 6 showingplatform members 1′ attached to connecting pieces 24 using bolts 25 andnuts 26.

FIG. 6B represents a lateral view of FIG. 6 showing platform members 1′attached to connecting pieces 24 using bolts 25 and nuts 26.

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

Considering the characteristics of this invention as explained above,the new pallet 10 is described in more detail next when read inconjunction with the accompanying drawings, in which:

Referring to FIGS. 1 and 2, this invention is identified as pallet 10that is configurable for different applications and load capacitiesdepending on the number and the thickness of the walls of the centralbeams 2 and platform members 1 and also depending on the thickness ofthe reinforcing ribs 3 and 9. Several central beams 2 are placedparallel to each other and connected with platform members 1 at the topand at the bottom sides of the beams 2. As shown in FIGS. 1 and 2, thenumber of platform members 1 at the top of beams 2 could be the same asor different to the number of members 1 at the bottom of beams 2. Thepallet model is specified by three numbers indicating the number ofplatform members 1 at the top, the number of central beams 2, and thenumber of platform members 1 at the bottom of the pallet 10; forexample, in FIG. 1, the platform 10 is a 543 model, which means that ithas five platform members 1 at the top, four central beams 2, and threeplatform members 1 at the bottom of the pallet 10. Similarly, FIG. 2 isa model 743 of the pallet 10.

FIGS. 1, 2 and 3 show the platform members 1 with a flat face 16 andflat sidewalls 17; on the side opposite to the flat face 16, it has agrid of ribs 9 longitudinal, transversal, and diagonally connected alongthe platform members 1; it has holes 4 to insert non-slip rubber blocks5 to prevent slippage of the pallet 10 and its cargo. Platform members 1also have holes 7 that are used to insert bolts 12 or 22; said holes 7have housing 15 to accommodate the heads 18 of bolts 12 and 22, thewashers 13, and the nuts 14. FIG. 3 shows several conical holes 11 onthe platform members 1 that are used to insert the conical protuberances8 of the central beams 2.

FIGS. 1, 2, 4 and 5 show the central beams 2 which have web 29, flatends 21 and flat surfaces 19 identical on its top and bottom sides, andboth of its lateral sides consist of grids of reinforcing ribs 3 thatare longitudinal, transversal, and diagonally connected along thecentral beams 2; located along the central beam 2 and centered on thetop and bottom flat surfaces 19, there are rows of conical protuberances8; between each pair of conical protuberances 8, there are holes 6,which are used to insert bolts 12 or 22 that also cross the platformmembers 1 through the holes 7; said conical protuberances 8 are insertedinto conical holes 11 on the platform members 1 to align and engage themand prevent relative displacement or rotation of the platform members 1and the central beams 2. Bolt 12 could be fully threaded as bolt 22 inFIG. 3A and in such case, holes 6 and 7 are also threaded to match bolt22. Bolts 12 or 22, washers 13 and nuts 14 are used to attach theplatform members 1 at the top and bottom of the central beams 2 to formthe pallet 10. Washers 13 can also be placed next to the head of thebolts 12 or 22, and between platform members 1 and beams 2.

FIG. 6 shows the platform member 1′, which is another embodiment ofplatform members 1 made without the holes 4; several of said platformmembers 1′ are placed adjacent to each other and attached withconnecting pieces 24 and at least four bolts 25 and nuts 26 to constructflat platforms 20 that are configurable in size depending on the numberof members 1′ and pieces 24 that are connected to each other. Platforms20 are made by attaching members 1′ and connectors 24 and they can beused as walls, floors, and molds for concrete pouring applications.Bolts 25 are inserted into holes 7 of the platform members 1′ thatcoincide with holes 27 of connecting parts 24 to form adjustable sizeflat platforms 20. As shown in FIG. 6A, connecting parts 24 have holes27 and protuberances 28 that match accommodations 15 in members 1′ toalign and secure them with bolts 25 and nuts 26. The platform members 1′and connecting pieces 24 have accommodations 15 to place the head ofbolts 25 and the nuts 26

The above description refers to the best embodiments of the objectivesand characteristics of the present invention. Various configurations andapplications of the new pallet can be obtained due to the versatility ofthe modular components that make up the new pallet 10. In addition,similar components 1′ to the platform members 1 of the new pallet 10 canbe connected to form walls, floors, and molds to pour concrete. All theinformation disclosed in here should be interpreted merely asillustrative and not in a restrictive sense for this invention.

1. A reusable, repairable, recyclable, with configurable load capacitypallet 10, characterized by having two main components: the centralbeams 2 and platform members 1 which have grids of reinforcing ribs 9and 3, respectively, whose thickness is adjustable in the manufacturingprocess to vary the strength and robustness of the pallet 10; several ofthese main components are interconnected, conical protuberances 8 onsaid central beams 2 are inserted into conical holes 11 in said platformmembers 1; at least two of the central beams 2 are placed in paralleland at their top and bottom sides they are aligned and coupledperpendicularly to a variable number of platform members 1; saidplatform members 1 and central beams 2 are secured and interlocked withbolts 12 or 22, washers 13, and nuts 14; said pallets 10 have emptyspaces 23 to insert the forks of a forklift or other pallet handler; thenumber and the thickness of the walls of said platform members 1 and/orcentral beams 2 is adjustable to configure the load capacity of thepallet 10; the thicknesses of the walls 16, 17, 19, and 21, web 29, andthe grids of reinforcing ribs 9 and 3 of said platform members 1 and/orcentral beams 2 are also adjustable to configure the load capacity ofthe pallet
 10. 2. The pallet 10 of claim 1 is characterized by havingcentral beams 2 which have flat ends 21, web 29, and flat surfaces 19that are identical at its top and bottom, with its lateral sides havinga grid of reinforcing ribs 3 longitudinal, transversal, and diagonallyconnected along the central beams 2; centered on the flat surfaces 19and located along the central beams 2, there are rows of conicalprotuberances 8; between each pair of conical protuberances 8, there areholes 6 that could be smooth or threaded to insert bolts 12 or
 22. 3.The pallet 10 of claim 1 is characterized by having platform members 1with a flat surface 16 and flat sidewalls 17; on the opposite side tothe flat surface 16, there is a grid of reinforcing ribs 9 longitudinal,transversal, and diagonally connected along the platform members 1; saidplatform members 1 have holes 7 to insert bolts 12 or 22; said holes 7have housings 15 to accommodate the heads 18 of bolts 12 or 22 or thenuts 14 and also to accommodate the washers 13; said holes 7 arethreaded to insert bolts
 22. 4. The pallet 10 of claim 1 ischaracterized by having non-slip rubber blocks 5 that are inserted intoholes 4 in the platform members 1 to prevent slippage of the pallet 10on the floor, shelf, or forklift or other pallet manipulating devices,and also to prevent slippage of the cargo on the pallet
 10. 5. Thepallet 10 of claim 1 is characterized by having aligning and engagingmeans consisting of conical protuberances 8 that are inserted in conicalholes 11 of platform members 1 to contribute carrying shear stresses andto prevent relative displacement or rotation between the platformmembers 1 and beams 2; pallet 10 also has interlocking and connectingmeans that consist of bolts 12 or 22, whose heads 18 are lodged in theaccommodations 15 at the ends of the holes 7 of the platform members 1,said bolts pass through holes 7 in platform members 1 and holes 6 in thecentral beams 2, and at the other end of the bolts 12 or 22, opposed tothe heads 18, washers 13 are placed, and nuts 14 are threaded onto thebolts 12 or 22 and lodged in the accommodations 15 at the ends of theholes 7 of the platform members 1; the washers 13 can also be placednext to the heads 18 of the bolts 12 or 22, and between platform members1 and beams
 2. 6. The pallets of claim 3 are characterized by formingflatbeds or platforms on the top and bottom of pallet 10; platformmembers 1 are modified by removing the holes 4 to create other platformmembers 1′; two or more of said platform members 1′ are placedadjacently and attached to each other using connecting pieces 24, bolts25, and nuts 26 to construct flatbeds 20 of adjustable size androbustness depending on the number of platform members 1′ and connectors24 that are connected together; said connecting pieces 24 have at leastfour holes 27 to coincide with holes 7 of the platform members 1′, saidconnecting pieces 24 have at least four protuberances 28 that areinserted into the accommodations 15 of the platform members 1′, saidbolts 25 are inserted into holes 7 of the platform parts 1′ that matchthe holes 27 in connectors 24 to assemble the adjustable size platform20; said connectors 24 have holes 27 and protuberances 28 that match theaccommodations 15 of members 1′ to align and secure them with bolts 25and nuts 26; said platforms 20 are used as walls, floors, and molds forconcrete pouring applications.